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6 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Reliability Estimation for Double Containment Piping

Double walled or double containment piping is considered for use in the ITER international project and other next-generation fusion device designs to provide an extra barrier for tritium gas and other radioactive materials. The extra barrier improves confinement of these materials and enhances safety of the facility. This paper describes some of the design challenges in designing double containment piping systems. There is also a brief review of a few operating experiences of double walled piping used with hazardous chemicals in different industries. This paper recommends approaches for the reliability analyst to use to quantify leakage from a double containment piping system in conceptual and more advanced designs. The paper also cites quantitative data that can be used to support such reliability analyses.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Engineering Scale Testing of Robotic Inspection Tools for Double Shell Tanks at Hanford - 18349

Waste found in the annulus of the AY-102 double-shell tank (DST) at Hanford has prompted the need for the development of inspection tools that are able to access confined spaces around and underneath the tanks. During the last year, Florida International University (FIU) has been developing inspection tools that are capable of accessing the tank floors through the air supply line, the air refractory channels and the drain lines. This effort has led to the development of a pneumatic pipe crawler and a miniature rover. In this paper, updates to the inspection tool designs and the full scale testing of both systems are presented. The tools provide visual feedback for the operator, carrying with them onboard cameras and light sources. The images are streamed back live via a tether, which also provides power to the devices. To increase the sensing capabilities of both tools, temperature, humidity and radiation sensor modules are being integrated onto the developed systems, and can be interchanged depending on the inspection objectives. The miniature rover measures 7 cm in length and 3.8 cm in width, and travels upside down on the bottom of the tank to avoid debris accumulated in the channels. The video is also being processed real-time to provide control of the unit semi-autonomously. The pipe crawler measures approximately 76 cm in length and 6.4 cm in diameter, and travels using pneumatic actuators that emulate the peristaltic movement contractions typical of worm type robots. A full-scale sectional mock-up of the DST foundation, refractory system and annulus is currently being developed as a test-bed for the testing of the inspection tools. The intention of the test-bed is to demonstrate the viability of using both inspection tools in configurations similar to the actual tank. The test-bed includes a 2.43 m wide section of both tank liners, refractory channels and concrete foundation with drain slots. The test-bed is designed to be modular so that various plate thicknesses can be easily utilized and different refractory configurations can be incorporated. Currently, the refractory channels are of the tree type structure with turns that are approximately 30 degrees. Both inspection tools were demonstrated in the mock-up facility. The miniature rover ran successfully through the drain slots from the annulus to central plenum and had no issues making the 90-degree turns. The peristaltic crawler was able to navigate through the 7.62 cm air supply line from the annulus to the central plenum. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Determining Drying Conditions to Mitigate Hanford Transfer Line Corrosion

Radioactive waste is stored in underground, carbon-steel double-shell tanks at the Department of Energy Hanford site.1,2,3 The underground transfer lines are used to transfer the waste between the tanks and other assets at the Hanford tank farm facilities. The transfer lines constructed before 1990 are pipe-in-pipe design with most of the lines having carbon steel carrier pipe and carbon steel encasements. The lines constructed after 1990 have a stainless-steel carrier with a carbon steel encasement. The carrier lines, which are in contact with the waste, provide a critical confinement function, while the encasements provide secondary containment to reduce the risk of a release and contamination to the environment. In 2022, a visual inspection of the annulus between the encasement and the carrier for one of the pre-1990 transfer lines revealed standing liquid in contact with the carrier pipe. Additionally, a significant build-up of corrosion products on the exterior of the carrier pipe and the interior of the encasement pipe was observed. To assess the extent of condition, borescope inspections were performed in the encasement space of additional transfer lines in the facility to provide a baseline. The inspection revealed that of the lines inspected, 29 had either moisture present or evidence that moisture had been present in the past (e.g., waterline corrosion where the pipe had been exposed to standing water). Additional inspections indicated several instances of pitting corrosion on the interior of the encasement and exterior the carrier transfer lines. An image of the carrier pipe with several pits is presented in Figure 1(a) and the profiled image of the transfer line section along with the pit depths are presented Figure 1(b). As seen in the figure, the deepest pit was 73 mils on the pipe section. These lines were designated as “do-not-use” until further compensatory actions are implemented to return the lines to service.

Shukla, Pavan K. [Savannah River National Laborato↗
DOE OSTI2018

A Prototype Dual Robot System to Perform Ultrasonic and Visual Inspection for the Bottom of Double-Shell Tanks - 18624

Up to this point, ultrasonic inspection-based condition data has only been available for double-shell tank (DST) sidewalls because direct inspection access to the primary tank bottom is limited to vent duct channels in an insulating refractory pad that the primary tank rests on. Probe access through the air slot would provide the opportunity to get information about the condition of the bottom of the primary tank, but it is a challenge to deploy a crawling robot that is capable of performing nondestructive ultrasonic and visual inspection through confined air slots. As such, a conceptual prototype of a deployable inspection robot system to enable ultrasonic and visual inspection for DST base through ventilation ducts was designed and fabricated. This prototype dual robot system consisting of the AnnulusBot and the MouseBot can be integrated with nondestructive evaluation (NDE) sensors to inspect and examine the physical properties of the underside of DSTs to enable status assessment. The AnnulusBot was designed to carry the MouseBot and to be deployed to the annulus space through a riser. To deploy the MouseBot to every ventilation channel in the annulus, the arm consisting of a boom and a forearm was used to place the MouseBot on the underside of the tank. The AnnulusBot used segmented wheels enable to traverse pipes and other potential obstacles. The cable management system utilized motorized wheels to feed the cable into the ventilation channel. This would reduce the amount of work that the MouseBot would have to do during inspection. This feeding mechanism would also be used to retrieve the MouseBot at the end of its inspection. Additionally, if the MouseBot fails, this mechanism would be used for retrieval. Once deployed, the MouseBot navigates to the center of the tank via the air ventilation channel beneath the inner shell (the primary tank) while inspecting the space. The MouseBot is then retrieved from the channel by a combination of its own drive power and the AnnulusBot retracting the attached umbilical cord. Compare with the AnnulusBot, the physical dimensional limitations of the MouseBot were a greater challenge. As the surface state of the concrete of the air channels could have variable texture, and may contain debris, it was decided not to travel along this surface. The ceiling of these channels is carbon steel and can be utilized throughout the channel. To use this travel surface, magnetic wheels were employed. A foreseeable problem with the use of magnets on this surface, is that they would preclude the use of eddy currents sensors. However, other technologies like ultrasonic technology sensors should be unaffected. Laboratory scale test was performed on a mock-up single wedge of the refractory pad to evaluate maneuverability of the MouseBot. The electronic components for the prototype would work in the ranges of 150-185 deg. F (65.6-85 deg. C). Both the AnnulusBot and MouseBot will be subject to constant radiation. All major printed circuit board (PCB) microcontroller components were designed to be situated outside of the annulus space and inside the main control panel to avoid radiation-induced failure. As future work, electronic components including the Arduinos that used Atmel commercial microcontrollers will be replaced with the high temperature rated Atmel microcontrollers so that the robots can be operated reliably at ambient temperatures up to 200 deg. F (93.3 deg. C). In addition, the robots will be service life tested to evaluate performance at elevated temperature and under gamma irradiation. (authors)

42 ENGINEERING↗
DOE OSTI2019

Waste Chemistry Envelope for the Determination of Pitting Corrosion Susceptibility - 19554

Liquid radioactive wastes at the Hanford and Savannah River sites are stored in large underground carbon steel tanks. The high-level wastes are processed in several of the tanks and then transferred by piping to other site facilities for further processing before they are stabilized in a vitrified or grout waste form. Based on waste removal and processing schedules, many of the tanks, will be required to be in service for times exceeding the initial intended life (i.e., greater than 60 years). Until the waste is removed from storage, transferred, and processed, the materials and structures of the tanks must maintain a confinement function by providing a barrier to the environment and by maintaining acceptable structural stability during design basis events, which include loadings from both normal service and abnormal (e.g., earthquake) conditions. Administrative programs are in place to mitigate potential corrosion mechanisms and thereby maintain the structural and leak integrity functions of these waste tanks throughout their intended service life. Waste chemistry and temperature control are the means by which corrosion degradation of the waste tanks is minimized. Chemistry controls are based on in-situ coupon tests, waste tank experience, and laboratory testing. These requirements comprise the technical standards for corrosion control. The standards are utilized then as guidelines for operational procedures. The present waste chemistry controls for the Hanford DSTs were established in the 1980's in response to tank failures caused by stress corrosion cracking (SCC) at the DOE Savannah River Site (SRS). Portions of the SRS chemistry limits, which were developed at the Savannah River National Laboratory (SRNL) were coupled with corrosion testing results from Pacific Northwest National Laboratories (PNNL) and adopted for corrosion control of the double-shell tank (DST) waste at the Hanford Site. Since that time, the temperatures of the waste in the DSTs have decreased to less than 50 deg. C in most cases as the radioactive material has decayed. As a consequence, new chemistry controls were formulated for SCC in 2010. This testing however, did not address that potential for pitting in the supernatant and at the liquid-air interface. Indeed, initial tests indicated that the inhibitor requirements for SCC would be insufficient for the prevention of pitting. In addition to lower waste temperatures, future retrieval and process changes may impact the DST waste chemistry. Initial projections suggest that the waste chemistry of the DSTs may shift to a broader range of pH and higher aggressive anion concentrations (e.g., chloride, sulfate, etc.) than the wastes that are presently stored. Additionally, processes within the vitrification facility may result in streams that are returned to the tank farm for evaporation. These streams may also contain high concentrations of aggressive species. SRNL investigated the propensity for pitting of the carbon steel waste tanks at current and projected DST waste chemistries. A statistically designed series of tests provided a pitting factor that relates the ratio of the inhibitor species to the aggressive species and the probability of observing pitting. An acceptable pitting factor was determined and was utilized for the development of a new chemistry envelope. The new chemistry envelope was compared to the envelope that was established for SCC and was determined to be bounding. Validation of the new chemistry envelope was performed via model simulations and comparison with historical experimental results and approaches to establishing chemistry envelopes. The new chemistry envelope will eventually be part of an overall assessment of the condition of the tanks and any changes made to the overall structural integrity program for the Hanford DSTs. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Discovery of the First Leaking Double-Shell Tank - Hanford Tank 241-AY-102

Full text - Long Abstract. A routine video inspection of the annulus region of double-shell tank 241-A Y-102 in August of 2012 indicated the presence material in the annulus space between the primary and secondary liners. A comparison was made to previous inspections performed in 2006 and 2007. which indicated that a change had occurred. The material was observed at two locations on the floor of the annulus and one location at the top of the annulus region where the primary and secondary top knuckles meet (RPP-ASMT-53793). Subsequent inspections were performed. leading to additional material observed on the floor of the annulus space in a region that had not previously been inspected (WRPS-PER-2012-1363). The annulus Continuous Air Monitor (CAM) was still operational and was not indicating elevated radiation levels in the annulus region. When the camera from the inspections was recovered. it also did not indicate increased radiation above minimum contamination levels (WRPS-PER-2012-1363). A formal leak assessment team was established August 10, 2012 to review tank 241-AY-102 construction and operating histories and to determine whether the material observed in the annulus had resulted from a leak in the primary tank. The team consisted of individuals from Engineering. Base Operations and Environmental Protection. As this was a first-of-its-kind task. a method for obtaining a sample of the material in the annulus was needed. The consistency of the material was unknown.and the location of a majority of the material was not conducive to using the sampling devices that were currently available at Hanford. A subcontractor was tasked with the development fabrication.and testing of a sampling device that would be able to obtain multiple samples from the material on the annulus floor. as well as the material originating from a refractory air-slot near the floor of the annulus space. This sampler would need to be able to collect and dispense the material it collected into a sample jar retrieval device for transportation of the material to the 222-S laboratory on the Hanford site for analysis. The subcontractor agency fabricated a remote underground sampler by modifying off-the-shelf robotics and parts. Limited testing of the sampler was conducted using a mock-up of the tank annulus and one simulated material type -a salt block. The mock-up testing indicated that the sampler would be able to maneuver within the confined space and that the device worked with full functionality. A total of six weeks had passed from initiation to implementation of the new sampler in the 241-AY-102 tank annulus. Initial sample material was obtained from the annulus floor using the Off-Riser Sampler System that has been used at Hanford tor years to obtain material from the primary tanks. This could be used at the location near Riser 83 since the material was collected directly from the annulus floor and not from a location on the wall or behind a pipe, as was needed from the two locations near Riser 90. After obtaining a small sample of the material on the annulus floor.this sampler sustained terminal damage due to conduit pipes it had to transverse in order to collect and recover material from this location. Several issues were also encountered during deployment of the new sampler into the annulus near Riser 90. These included: Difficulty fitting the sampler down the 12-inch riser into the annulus due to a small tolerance in the size of the sampler; Failure of sampler components and functions during deployment including the camera. pneumatics.and bearing seals; Delays in the field due to supporting equipment issues including cables. cameras. and scaffolding; and, Low recovery of sample material obtained for analysis. The complications that occurred during deployment and use of the new sampler during the sampling event ultimately resulted in lower recovery of material from these locations in the annulus than was obtained using the Off-Riser Sampler System and limited the analyses that could be performed for determining the origin of the material. Following completion of the sample analyses and the assessment of its construction history and use. there was a consensus among the leak assessment team members that two of the three materials sampled from the annulus floor region were the result of waste leaking from a breach in the primary tank. The probable leak cause was identified as corrosion at high temperatures in a tank whose containment margins had been reduced due to construction difficulties (RPP-ASMT-53793). A formal Lessons Learned was created concerning designing equipment tor unique purposes under time constraints. This document was published in OPEXShare on May 20. 2013. It highlighted some of the issues that arose with the subcontractor sampler development and provided recommendations to prevent a recurrence should this task need to be performed again in the future. The document can be found at http://msa.hanford.gov/opex/lesson.cfm/2013/5/20/3481/AY-102-Annulus-Sampler-Designing-Equipment-for-Unique-Purposes-under-Time-Constraints/.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗